Penetrode Offroad
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I love your work 
Project: Midnight Panic
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Skipped_Link
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For both the nitrous fuel, & main fuel systems I am using an aftermarket fuel pressure regulator that is a direct replacement for the old Ford EFI systems, this style regulator normally bolts to the fuel rail, so using it in about any other application requires a little creativity,
On the old tank & had built a block that housed the fuel passages, & mounted the regulator, that block was them welded into the tank,
I did something similar for this this tank, except the block bolts on,
For mounting the tank I kept the original tray that the old tank sat on, I simply had to add a small section to accommodate the extended back portion of the new tank, That was relativly easy, actually holding the tank could have been easy too, the old tank was held in place with a pair of straps, like 90% of fuel tanks out there,
But rather than build a new pair of straps, I ended up machining a couple aluminum bars that fit around a removable chassis bar, once in place they actually pivot on the bar, down onto the top of the new tank, a couple threaded links pull the new aluminum bars now from the bottom tray at the front of the tank, I didn't really get any specific pics of this setup, but it ended up being pretty stout,
The last step was replumbing the new tank into the engine,
Turns out I do not have any #4 braided hose to replumb the nitrous fuel, so I'll get to that later,
In the above pic you can see the top right corner of the fuel tank has a section left full thickness with two threaded holes,
This was done in case I have to switch over to a front steer pump that requires a remote reservoir, I'll have a place to mount it,
You can also see the new tank hold downs,
Finally, after many long days we got to fire it up,
Test drives & tuning are next up, Gotta have this thing ready for Havoc early next month.
On the old tank & had built a block that housed the fuel passages, & mounted the regulator, that block was them welded into the tank,
I did something similar for this this tank, except the block bolts on,
For mounting the tank I kept the original tray that the old tank sat on, I simply had to add a small section to accommodate the extended back portion of the new tank, That was relativly easy, actually holding the tank could have been easy too, the old tank was held in place with a pair of straps, like 90% of fuel tanks out there,
But rather than build a new pair of straps, I ended up machining a couple aluminum bars that fit around a removable chassis bar, once in place they actually pivot on the bar, down onto the top of the new tank, a couple threaded links pull the new aluminum bars now from the bottom tray at the front of the tank, I didn't really get any specific pics of this setup, but it ended up being pretty stout,
The last step was replumbing the new tank into the engine,
Turns out I do not have any #4 braided hose to replumb the nitrous fuel, so I'll get to that later,
In the above pic you can see the top right corner of the fuel tank has a section left full thickness with two threaded holes,
This was done in case I have to switch over to a front steer pump that requires a remote reservoir, I'll have a place to mount it,
You can also see the new tank hold downs,
Finally, after many long days we got to fire it up,
Test drives & tuning are next up, Gotta have this thing ready for Havoc early next month.
rattle_snake
Fuckwits
gt1guy
Apparently a racist
Fantastic work as always.
For some reason I'm totally not surprised you hit it with N2O
For some reason I'm totally not surprised you hit it with N2O
ridered3
Low Talent Wheelin
Amazing work and detail! How many gallons does the new cell hold and how long would a single tank of gas last for Havoc?
Skipped_Link
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It's been a crazy busy few weeks, I'll go ahead & document that here for those interested, For those that are not, the last couple lines of this post will get you up to speed on this build,
When I last posted I was ready for test drives & tuning on the new engine, well the first couple test drives went great! The new engine ran so good,
I'm just going to copy & paste my FB recount of the events leading up to the Havoc event this year.
"After several years of joking around about how little maintenance I have to perform before the big show, karma finally started joking back with a couple major failures in 2021 & 2022,
This year I planned the long overdue new engine, & better accessory drive, to go along with the new transfer case that was installed the end of last year,
Unfortunately after many long hours I was still going be kicked right in the guts.
Engine assembly & installation, while time consuming, went well,
Same with all the fab work involved in the new belt drive system, & completely new steering pump system, followed by the new fuel cell,
The new engine ran awesome, & even before fine tuning was looking to exceed our expectations,
While confirming ignition timing (Not even 10 minutes into the first tuning session) the new engine developed a pretty bad noise,
I shut it down immediately & began investigating,
Turns out a brand new Comp roller lifter come apart, ruining any chance of this engine running this year.
This was basically the last set of days off to actually work on the rig & have it ready to go.
After talking with my “engine consultant”
We decided a visual inspection & new bearings in the ole 513 before re-installing it would be the best chance of me still making it to Havoc.
An early trip to Reno the next day I was able to get a set of bearings & gaskets from summit racing, & be back to the shop before noon, plenty of time to roll bearings in before calling it a day, right?
Maybe, if I didn’t notice the crank shaft was able to turn about 45° back & forth without the camshaft moving,
Closer inspection there found a broken cam dowel pin,
Thankful that catastrophe didn’t fully play out, I removed the upper timing gear, & all 3 pieces of the dowel, set the gear up in the mill & drilled a second hole 180° from the original, followed by doing the same to the camshaft,
After installing TWO new dowel pins & a better retaining washer, I was feeling pretty good about the repair & looking forward to finally getting those new bearings installed,
However, in the famous words of Billy Mays, “but wait, there’s more!”
While doing a final inspection of my work at the front of the engine, something caught my eye, & sure enough, this engine too had a damaged lifter, not to the point of the new engine, but it was well on its way,
(Right about this point is probably the 4th time I said “I’m done”)
Oddly enough, my normally pessimistic yet great friend & "engine consultant" popped off with “well you do have that set of lifters you saved out of your car”
So I continued on
Running out of days (and parts) my second to last day off included putting in new/used lifters, reinstalling pushrods, rockers, girdles, & setting the over head,
Then finally installing those damn bearings, & sealing it up with an intake, oil pan, & rocker covers,
Finishing the day with a personal best of 2 hours to remove the engine out of the buggy, & remove the remaining parts I would need off of it.
My last day off, got the engine installed & the buggy back to a runable state,
After a week at work, this weekend was supposed to be for getting loaded & ready for the trip, but I still needed a tune for the buggy, & long story short, uploading the old tune just wasn’t an option,
Fortunately, Josh West worked his magic,
And in less time it took me to wreck the last engine, he had this one dialed right back in,
I also have to thank my wife for getting a few things done that I simply wouldn’t have got to.
So here we are, one more full day to make sure everything is good, & get loaded,
I’m not sure what I’m bringing this year,,,but I’m bringing what I got."
The following weekend we made the long trip to Bonners Ferry ID for the 3 day event, the buggy ran flawlessly, & even though I made a couple petty mistakes, my co-driver & I were able to land a solid 4th place finish overall out of 21 solid rigs & competitors,
The two most difficult courses were where we performed the strongest, so I was real happy with that,
(Here's a pretty good video of our rock course run)
So, Where I'm sitting now, I'm certain the engine guy is going to want to tear the 528 down & get going on that, however, right now I'm really considering putting all the buggy/event stuff on the back burner & focus on the project this thread is about,
I feel this project needs to get done,
I do have a new tool that I purchased a few weeks ago that I need to get setup (more on that in upcoming posts) hopefully that will be up and running next weekend, make a few small repairs to the buggy, then back to full steam on the Midnight panic project.
When I last posted I was ready for test drives & tuning on the new engine, well the first couple test drives went great! The new engine ran so good,
I'm just going to copy & paste my FB recount of the events leading up to the Havoc event this year.
"After several years of joking around about how little maintenance I have to perform before the big show, karma finally started joking back with a couple major failures in 2021 & 2022,
This year I planned the long overdue new engine, & better accessory drive, to go along with the new transfer case that was installed the end of last year,
Unfortunately after many long hours I was still going be kicked right in the guts.
Engine assembly & installation, while time consuming, went well,
Same with all the fab work involved in the new belt drive system, & completely new steering pump system, followed by the new fuel cell,
The new engine ran awesome, & even before fine tuning was looking to exceed our expectations,
While confirming ignition timing (Not even 10 minutes into the first tuning session) the new engine developed a pretty bad noise,
I shut it down immediately & began investigating,
Turns out a brand new Comp roller lifter come apart, ruining any chance of this engine running this year.
This was basically the last set of days off to actually work on the rig & have it ready to go.
After talking with my “engine consultant”
We decided a visual inspection & new bearings in the ole 513 before re-installing it would be the best chance of me still making it to Havoc.
An early trip to Reno the next day I was able to get a set of bearings & gaskets from summit racing, & be back to the shop before noon, plenty of time to roll bearings in before calling it a day, right?
Maybe, if I didn’t notice the crank shaft was able to turn about 45° back & forth without the camshaft moving,
Closer inspection there found a broken cam dowel pin,
Thankful that catastrophe didn’t fully play out, I removed the upper timing gear, & all 3 pieces of the dowel, set the gear up in the mill & drilled a second hole 180° from the original, followed by doing the same to the camshaft,
After installing TWO new dowel pins & a better retaining washer, I was feeling pretty good about the repair & looking forward to finally getting those new bearings installed,
However, in the famous words of Billy Mays, “but wait, there’s more!”
While doing a final inspection of my work at the front of the engine, something caught my eye, & sure enough, this engine too had a damaged lifter, not to the point of the new engine, but it was well on its way,
(Right about this point is probably the 4th time I said “I’m done”)
Oddly enough, my normally pessimistic yet great friend & "engine consultant" popped off with “well you do have that set of lifters you saved out of your car”
So I continued on
Running out of days (and parts) my second to last day off included putting in new/used lifters, reinstalling pushrods, rockers, girdles, & setting the over head,
Then finally installing those damn bearings, & sealing it up with an intake, oil pan, & rocker covers,
Finishing the day with a personal best of 2 hours to remove the engine out of the buggy, & remove the remaining parts I would need off of it.
My last day off, got the engine installed & the buggy back to a runable state,
After a week at work, this weekend was supposed to be for getting loaded & ready for the trip, but I still needed a tune for the buggy, & long story short, uploading the old tune just wasn’t an option,
Fortunately, Josh West worked his magic,
And in less time it took me to wreck the last engine, he had this one dialed right back in,
I also have to thank my wife for getting a few things done that I simply wouldn’t have got to.
So here we are, one more full day to make sure everything is good, & get loaded,
I’m not sure what I’m bringing this year,,,but I’m bringing what I got."
The following weekend we made the long trip to Bonners Ferry ID for the 3 day event, the buggy ran flawlessly, & even though I made a couple petty mistakes, my co-driver & I were able to land a solid 4th place finish overall out of 21 solid rigs & competitors,
The two most difficult courses were where we performed the strongest, so I was real happy with that,
(Here's a pretty good video of our rock course run)
So, Where I'm sitting now, I'm certain the engine guy is going to want to tear the 528 down & get going on that, however, right now I'm really considering putting all the buggy/event stuff on the back burner & focus on the project this thread is about,
I feel this project needs to get done,
I do have a new tool that I purchased a few weeks ago that I need to get setup (more on that in upcoming posts) hopefully that will be up and running next weekend, make a few small repairs to the buggy, then back to full steam on the Midnight panic project.
holdmypocket
nil
Great update.. anyone else inspired to go wrench on their project and get shit done? 
gt1guy
Apparently a racist
How do multiple lifters in different engines fail in exactly the same spot? That is certainly strange.
Generally it's the needle bearings in the roller wheel that let got, not the body.
Generally it's the needle bearings in the roller wheel that let got, not the body.
Skipped_Link
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I think it was two different types of failures,
I believe the brand new lifter in the new engine let the clip out that holds the roller axle in the body,
This let that pin/axle walk out until it hit the bottom of the lifter bore, breaking the body,
The old lifter was probably a design or fatigue issues, (or both)
Both are the same brand (Comp) & research shows they have a serious issue with their lifters the last several years.
I believe the brand new lifter in the new engine let the clip out that holds the roller axle in the body,
This let that pin/axle walk out until it hit the bottom of the lifter bore, breaking the body,
The old lifter was probably a design or fatigue issues, (or both)
Both are the same brand (Comp) & research shows they have a serious issue with their lifters the last several years.
chaplinfj60
Well-known member
i thought you had a black buggy 
great update and wow that was serious perseverance for sure.
great update and wow that was serious perseverance for sure.
WaterH
Well-known member
Good up date. One issue, the video would not play unless I allow cookies that let FB track me. I won’t do that. Would be nice if you could post it somehow that I don’t have to do that.
ridered3
Low Talent Wheelin
Great update in general and some amazing dedication to do all that engine swap stuff in order to compete!
Skipped_Link
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That video might possibly end up on YouTube, if that’s the case I’ll post a link to it.
Skipped_Link
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Hopefully this is my last "non-mudtruck realted update"
I posted earlier about a new tool, which I ordered & recieved over a month ago, However buggy prep & Havoc kept me from even really unboxing it,
Several years ago I seen a ad for the "X-carve" CNC router, Having used a router & router tooling quite a bit on aluminum I thought this might be a viable option for small parts that would normally require multiple setups to build on a manual machine,
I found out that the operating system for this machine (Easle) at the time was a rent to use program, that killed that idea pretty quick,
Not much I dislike more than renting a computer program,
Jump ahead a couple years & I run across a used Shapeoko 3 CNC router table on FB market place, I asked the seller about the operating system & he claimed they used their own system (Carbide create) for creating projects, & for running the machine (Carbide motion)
This info drug me down the rabbit hole, & much deeper rabbit hole than I have the time to dedicate to the topic,
What I did learn was Carbide 3D does build machines, several different sizes, models, & levels of capabilities. (The 3 being an older model)
Their operating systems are in fact free, with a more advanced/capable version available in a paid version,
At first I settled on a Shapeoko 4 (still an older model) but when I went to order a couple of the upgrades were on back order, so I blew it off,
Pretty much the entire time I was building the new accessory drive for the buggy & thought to myself, "If I had that machine & new how to run it, this job would be a lot easier"
So I started the ordering process again, this time deciding on the 4 pro, but before I hit the pay it now button I had talked myself to their most recent model, in a midsize package & a couple nice upgrades, (5 Pro with a VFD spindle)
One of the bigger hurdles when getting a tool like this is finding a place for it, (the machine I ordered has a 24"x48" working area, & a 35"x60" footprint, So mobility was a must,
The quickest/easiest option was a new top for one of my old tool boxes,
Machine assembly was dead simple, especially compared to most of my projects around here, If it wasn't for me being indecisive on VFD loaction, I would have this thing running in a couple hours,
A couple Youtube tutorials along with a little messing around & I was already making chips, mostly wood chips so far,
I think this is the first time I've put my own logo on something, besides a sticker,
Early testing on aluminum looks pretty promising,
I have a video taking cuts on some 1/2" 6061, I'll see if I can post that directly so you guys don't have to go to FB to see it,
I posted earlier about a new tool, which I ordered & recieved over a month ago, However buggy prep & Havoc kept me from even really unboxing it,
Several years ago I seen a ad for the "X-carve" CNC router, Having used a router & router tooling quite a bit on aluminum I thought this might be a viable option for small parts that would normally require multiple setups to build on a manual machine,
I found out that the operating system for this machine (Easle) at the time was a rent to use program, that killed that idea pretty quick,
Not much I dislike more than renting a computer program,
Jump ahead a couple years & I run across a used Shapeoko 3 CNC router table on FB market place, I asked the seller about the operating system & he claimed they used their own system (Carbide create) for creating projects, & for running the machine (Carbide motion)
This info drug me down the rabbit hole, & much deeper rabbit hole than I have the time to dedicate to the topic,
What I did learn was Carbide 3D does build machines, several different sizes, models, & levels of capabilities. (The 3 being an older model)
Their operating systems are in fact free, with a more advanced/capable version available in a paid version,
At first I settled on a Shapeoko 4 (still an older model) but when I went to order a couple of the upgrades were on back order, so I blew it off,
Pretty much the entire time I was building the new accessory drive for the buggy & thought to myself, "If I had that machine & new how to run it, this job would be a lot easier"
So I started the ordering process again, this time deciding on the 4 pro, but before I hit the pay it now button I had talked myself to their most recent model, in a midsize package & a couple nice upgrades, (5 Pro with a VFD spindle)
One of the bigger hurdles when getting a tool like this is finding a place for it, (the machine I ordered has a 24"x48" working area, & a 35"x60" footprint, So mobility was a must,
The quickest/easiest option was a new top for one of my old tool boxes,
Machine assembly was dead simple, especially compared to most of my projects around here, If it wasn't for me being indecisive on VFD loaction, I would have this thing running in a couple hours,
A couple Youtube tutorials along with a little messing around & I was already making chips, mostly wood chips so far,
I think this is the first time I've put my own logo on something, besides a sticker,
Early testing on aluminum looks pretty promising,
I have a video taking cuts on some 1/2" 6061, I'll see if I can post that directly so you guys don't have to go to FB to see it,
Skipped_Link
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Firstram
Well-known member
Now it will be faster and easier for you to make the rest of us look like hacks
Skipped_Link
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I'm using a glorified router to build parts, I have no room to call anyone else a hackNow it will be faster and easier for you to make the rest of us look like hacks
Firstram
Well-known member
Of course not, your work speaks volumesI'm using a glorified router to build parts, I have no room to call anyone else a hack
gt1guy
Apparently a racist
If you want to know how to get tinnitus, listening to that for hours is how you get tinnitus.
That was loud on my end of the video
That was loud on my end of the video
Skipped_Link
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This project finally ended up back in the working side of the shop.
After jimmy rigging a radiator & spare water pump into the rig, I was able to run the engine a little longer now that it has coolant,
Being able to run it longer & build heat in components like connecting rods & valve train also means I get to bump the throttle a bit, & that always makes an everyone feel good.
This last week I invested a few hours in welding some tabs & brackets for future mud proofing, then began clearing out shelf & storage area so I have room to store a disassembled truck while finish work is being done.
Next week small tab & mount installation will continue, & I may even get started on the tear down process,
4 wheel shop throttle blips are getting closer
After jimmy rigging a radiator & spare water pump into the rig, I was able to run the engine a little longer now that it has coolant,
Being able to run it longer & build heat in components like connecting rods & valve train also means I get to bump the throttle a bit, & that always makes an everyone feel good.
This last week I invested a few hours in welding some tabs & brackets for future mud proofing, then began clearing out shelf & storage area so I have room to store a disassembled truck while finish work is being done.
Next week small tab & mount installation will continue, & I may even get started on the tear down process,
4 wheel shop throttle blips are getting closer
Engine sounds killer, love the sound of blower whine.
gt1guy
Apparently a racist
Who needs tunes in the shop when you can just have that idling.
Penetrode Offroad
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I love that its shaking the camera at idle. Sounds great!
Skipped_Link
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If it didn't seem like I was backing up on this project before, it sure looks like it now,
But tear down for finish work on a project has always been a little light at the end of the tunnel for me, & that's where I'm at,
First, I needed a place to put everything, so both sides of the shop get a little cleaning & reorganizing,
Next I had a coupe loose ends to tie up before disassembly, mostly little stuff like cutting out & tacking in a couple more cab mounting tabs,
One project I've known needed done for a while is the front rotor guard, when I built it I had used a different slip yoke on the drive line, but then switched to a longer tavel yoke/spline assembly, this resulted in a clearance issue when the guard was bolted on,
Rather than grind out the material, I set it up in the mill & knocked it out with a fly cutter real quick,
A few minutes later there was plenty of room,
Then the slow process of disassembly began,
You'd think this would go quick, but I've never taken this one apart before, & this time around I'm labeling or documenting most of the pieces as they come off & go on the shelf,
The kiddo & I did run in to the powder coat shop, discussed colors, & dropped the first small pallet of parts off for finish work,
Next week disassembly will continue, & maybe even get started on some finish welding,
But tear down for finish work on a project has always been a little light at the end of the tunnel for me, & that's where I'm at,
First, I needed a place to put everything, so both sides of the shop get a little cleaning & reorganizing,
Next I had a coupe loose ends to tie up before disassembly, mostly little stuff like cutting out & tacking in a couple more cab mounting tabs,
One project I've known needed done for a while is the front rotor guard, when I built it I had used a different slip yoke on the drive line, but then switched to a longer tavel yoke/spline assembly, this resulted in a clearance issue when the guard was bolted on,
Rather than grind out the material, I set it up in the mill & knocked it out with a fly cutter real quick,
A few minutes later there was plenty of room,
Then the slow process of disassembly began,
You'd think this would go quick, but I've never taken this one apart before, & this time around I'm labeling or documenting most of the pieces as they come off & go on the shelf,
The kiddo & I did run in to the powder coat shop, discussed colors, & dropped the first small pallet of parts off for finish work,
Next week disassembly will continue, & maybe even get started on some finish welding,
Blacksheep10
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Didn’t want to top this and dash everyone’s hopes with a notification. I found this last week and chewed through it by yesterday. When I started and it was a couple years ago, I was excited for the vids of it launching by 2023!!
Badass work, what a journey the thread has been. Thanks for taking us along
Badass work, what a journey the thread has been. Thanks for taking us along
Firstram
Well-known member
And ya bumped it anyway
ridered3
Low Talent Wheelin
Ha he respectfully bumped it after a real update so that’s got be worth something right?And ya bumped it anyway
Unlike this post of course…
Skipped_Link
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More disassembly,
I was pleasantly surprised by how smoothly the cab came off,
My cribbing/rigging could use some refining, but I’ll worry about that at reassembly time,
A little forklift action got the project moved into a bay in the shop that has a bit better access to my overhead hoist,
But, while it was out in the sun I had to get a nude shot.
The engine & transmission was just the start, by the end of the day today I had every component & fastener that could be removed pulled out of the chassis,
A friend of mine let me borrow his rotisserie, & after whipping up a couple new adapters it looks like it should work well for finish welding, & even better for sandblast & powder coat after that,
I’ve got about a day of cleanup & figuring out any additional parts needed, then back to work for 5,
Maybe by this time next week this thing will be ready for color.
I was pleasantly surprised by how smoothly the cab came off,
My cribbing/rigging could use some refining, but I’ll worry about that at reassembly time,
A little forklift action got the project moved into a bay in the shop that has a bit better access to my overhead hoist,
But, while it was out in the sun I had to get a nude shot.
The engine & transmission was just the start, by the end of the day today I had every component & fastener that could be removed pulled out of the chassis,
A friend of mine let me borrow his rotisserie, & after whipping up a couple new adapters it looks like it should work well for finish welding, & even better for sandblast & powder coat after that,
I’ve got about a day of cleanup & figuring out any additional parts needed, then back to work for 5,
Maybe by this time next week this thing will be ready for color.
ridered3
Low Talent Wheelin
Can't decide which of those pictures is more badass!